Electrical box for ceiling fans

ABSTRACT

A ceiling fan box adapted to be mounted on a structural member, such as a ceiling joist, and adapted to provide a ceiling fan direct securement to the structural member. The ceiling box includes a body having a lower surface and a pair of spaced apart opposed side members defining a recess therebetween for receiving the structural member therein. An aperture formed through the lower surface for receiving a fastener therein for securement to the structural member for supporting the body thereon. A pair of spaced apart openings formed through the lower surface for receiving a respective pair of fan supporting fasteners therethrough for directly securing a fan to the structure member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.10/146,995, filed May 16, 2002; and claims priority to U.S. ProvisionalApplication No. 60/293,439 filed on May 24, 2001 and U.S. PatentApplication No. 60/374,895, filed on Apr. 23, 2002.

FIELD OF THE INVENTION:

The present invention relates generally to an electrical box mountableon the ceiling for supporting a ceiling fan. More particularly, thepresent invention relates to a ceiling fan box which is mountabledirectly to a ceiling joist.

BACKGROUND OF THE INVENTION

In order to mount ceiling fans, ceiling fan boxes are typically used. Aceiling fan box which is attachable to a ceiling joist or other supportin the ceiling generally serves two functions. First, it encloses theelectrical wire terminations which are made between the ceiling fan andthe electrical power run to the ceiling fan. Second, the ceiling fan boxsupports the ceiling fan during operation. Such boxes may be used withexisting construction (old work) where the ceiling fan is beinginstalled in a finished area, or during construction (new work) wherethe ceiling fan may be installed prior to installation of the ceiling.In either case, it is necessary to attach the ceiling fan box to theceiling joist or other ceiling supported structure. It may beappreciated that working overhead in a ceiling is difficult. Thus, themethod of attaching the ceiling fan box to the ceiling joist, iscritical with respect to both convenience and time savings.

Moreover, the ceiling fan box must be of construction which canwithstand the dynamic load imparted by the ceiling fan which is attachedthereto. Such dynamic loads may also include loads imparted by anunbalanced ceiling fan.

It is therefore desirable to provide a ceiling fan box which may beeasily attached to a ceiling structure such as a ceiling joist and whichsecurely supports the ceiling fan therefrom.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of an improved electrical ceiling fanbox of the present invention.

FIG. 2 is a lower perspective showing of the electrical ceiling fan boxof FIG. 1.

FIGS. 3 and 4 show respectively a top perspective and bottom perspectiveview of a further embodiment of the electrical ceiling fan box of thepresent invention.

FIGS. 5 and 6 show top and bottom perspective views, respectively of astill further embodiment of the electrical ceiling fan box of thepresent invention.

FIG. 7 shows a top perspective view of another embodiment of theelectrical ceiling fan box of the present invention.

FIG. 8 shows a top plan view of the ceiling fan box of FIG. 7.

FIG. 9 shows a top perspective view of yet another embodiment of theelectrical ceiling fan box of the present invention.

FIG. 10 shows a top perspective view of still yet another embodiment ofthe electrical ceiling fan box of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention provides a ceiling fan box which is attachable toa ceiling joist for supporting a ceiling fan therefrom. The electricalceiling box of the present invention is an improvement in boxes of thetype generally shown and described in U.S. Pat. No. 5,234,119, issuedAug. 10, 1993 and U.S. Pat. No. 4,874,905, issued Oct. 17, 1989, thedisclosures of each are being incorporated by reference herein for allpurposes.

Referring now to FIGS. 1 and 2, an embodiment of the electrical ceilingbox of the present invention is shown. While referred to as a box, theceiling fan box 10 of the present invention is general cylindrical inshape and includes a body 12 having a planar lower surface 14, a pair ofupstanding side members 16 and 18 on either side of lower surface 14.The side members 16 and 18 and the lower surface 14 define a generallyU-shaped recess 20 for accommodating a ceiling joist (not shown)therein. Side members 16 and 18 include facing side walls 16 a and 18 awhich are spaced apart a distance generally equivalent to the width of aceiling joist. The ceiling joist is inserted into recess 20 and isfrictionally retained therein by frictional engagement with walls 16 aand 18 a. In order to assist in the frictional retention of the body 12about the joist, the side walls 16 a and 18 a include a plurality ofspaced apart elongate outwardly extending ribs 22 therealong. The ribs22 help to provide frictional engagement with the opposed side surfacesof the joist which is inserted into recess 20. Side members 16 and 18further include a plurality of wire entry apertures 24 which may beenclosed by frangibly removable covers 24 a. The apertures 24 permitinsertion of wires into hollow cavities 26 defined by side members 16and 18.

As shown in FIG. 2, wire terminations for attachment to a ceiling fanmay be made in the recesses 26 and the area 28 defined by the oppositeside 14 a of lower surface 14. Side members 16 and 18 further includeknockout openings 30 and 32, respectively, which include frangiblyremovable covers 30 a and 32 a which are also designed to permit wireentry. Once the covers are removed, the knockouts can support anelectrical nipple which facilitates wire entry.

Lower surface 14 includes a centrally located aperture 40 and a pair ofelongate openings 42 and 44. Openings 42 and 44 extend from adjacent theperipheral edge of body 12 and extend through surface 14.

Box 10 may be inserted onto a stud by placing the box in a straddlingposition around the ceiling joist with the ceiling joist beingfrictionally retained within recess 20 thereof. Frictional retention isprovided by the engagement between the walls 16 a and 18 a of sidemembers 16 and 18 with the opposed side surface of the joist. The box 10is inserted until the lower surface 14 rests against the lower edge ofthe joist. In this position, while the outlet box is frictionallyretained on the joist, the outlet box may be more securely fastenedthereto by inserting an appropriate fastener such as a wood screwthrough aperture 40 and into the face of the joist.

Once the box is securely fastened to the joist, the ceiling fan may besupported directly to the joist through the box. This is accomplished byinserting the fastening hardware, such as wood screws, of the ceilingfan through openings 42 and 44 and directly into the face of the joistagainst which the box is supported. The elongate openings 42 and 44allow for adjustable positioning so as to help properly align theceiling fan. Thus, the ceiling fan is supported directly to the joistthrough the ceiling box and the ceiling box need not be relied upon forsupport of the ceiling fan. The box, however, provides an adequateenclosure for housing the wire terminations to the ceiling fan.

The present invention further provides a pair upwardly directed spacedapart extensions 50 along each side wall 16 a and 18 a of side members16 and 18. Extensions 60 are flush with side walls 16 a and 18 a so thatthey are positioned along the opposed sides of the joist. Each extension60 includes an aperture 62 therethrough through which an appropriatefastener such as a wood screw may be inserted to more securely retainthe box on the joist.

Referring now to FIGS. 3 and 4, a further embodiment of the presentinvention is shown. The embodiment in FIGS. 3 and 4 is similar to theembodiment shown in FIGS. 1 and 2, however, a 45° opening is shown inthe lower portion of the side members to allow insertion of a wood screwor similar fastening hardware to secure the box to the sides of thejoist inserted therein.

FIGS. 5 and 6 show a still further embodiment of the box of the presentinvention. The embodiment of FIGS. 5 and 6 is substantially similar tothe embodiment of FIGS. 3 and 4, but provides a different arrangementfor the apertures for mounting the ceiling fan.

Another embodiment of the box of the present invention as shown in FIG.7 is substantially similar to the embodiment of the previous figures,but provides a screw retention feature 85 to temporarily hold screws 80to the ceiling fan box 10 f prior to use. In this embodiment, as shownin FIG. 7, the screw retention structure 85 preferably includes two pairof flexible prongs, uprights or clips 81 which removably secure thescrews 80 against the wall structure 84 of the elongated boss definingopening 44 f. Screw 80 is secured by clips 81, which wrap around aportion of the screw and cause the screw to press against the wallstructure 84. The distance between the clips 81 and the wall structure84 is far enough for placement of a screw without undue stress andtension of the wall structure 84 and clips 81; yet it is close enough toremovably secure the screw 80 but prevent dislodgement during shipment.

One aspect of the retention feature 85 is that the screws 80 aredetachable by a user, such as an electrician, to employ duringinstallation of the electrical box 10 f. While the screw retentionfeature 85 is shown as using the wall structure 84, it should also beappreciated that other structures of the box, such as central boss 86,may be used to provide the screw retention feature.

As shown in FIG. 8, box 10 f has a central opening 40 k extendingthrough central boss 86. The opening 40 k is provided with a flattenedsurface 43 k such that the aperture 40 k appears to have a “D” shape.Such “D” shaped opening provides for further screw holding capability.It should be appreciated that the flat surface 43 k may be located atany surface defining the aperture 40 k.

Yet another embodiment of the ceiling fan box is shown in FIG. 9. Box 10g is substantially similar to the box of FIGS. 7 and 8, but provides adifferent shape to the body of the electrical box. The box 10g isgenerally cylindrical in shape and includes a body 12 g having a rim 90extending circumferentially around the upper end 14 g thereof. A pair ofside members 16 g and 18 g extend downwardly from either side of theupper end 14 g. The rim 90 has a diameter extending outwardly radiallybeyond the outer surfaces of side members 16 g and 18 g such that theside members 16 g and 18 g appear to be recessed within the rim 90.

FIG. 10 shows yet still another embodiment of the present invention.FIG. 10 is substantially similar to FIGS. 7 and 8, however, a collar orflange 100 is shown extending outwardly around the body 12 h of the box10 h. Flange 100 extends fully circumferentially around the periphery ofthe upper end 14 h of the box 10 h. A strip of insulating material, suchas foam 101, may be provided on the upper surface of flange 100 tocreate a seal in conjuction with the ceiling wallboard for enhancingenergy efficiency.

1. A ceiling fan box for mounting on a structural member comprising: abody having a lower surface and a pair of spaced apart opposed sidemembers defining a recess therebetween for receiving said structuralmember therein; an aperture formed through said lower surface forreceiving a fastener therein for securement to said structural memberfor supporting said body thereon, and a pair of openings formed throughsaid lower surface for receiving a respective pair of fan supportingfasteners therethrough for directly securing a fan to said structuralmember.
 2. A ceiling fan box of claim 1, wherein said side walls eachhave a mount opening therethrough for receiving a fastener to securesaid box to a side of said structural member.
 3. A ceiling fan box ofclaim 2, wherein each said mount opening has a 45 degree angle from saidsurface of said sidewall therethrough.
 4. A ceiling fan box of claim 1,wherein said openings are disposed with one opening each on oppositesides of said aperture.
 5. A ceiling fan box of claim 4, wherein saidaperture and said pair of openings are substantially linearly aligned.6. A ceiling fan box of claim 4, wherein said openings of each pair areelongated.
 7. A ceiling fan box of claim 6, wherein said pair ofopenings are located at a peripheral edge of said body.
 8. A ceiling fanbox of claim 7, wherein said aperture is generally centrally located insaid lower surface.
 9. A ceiling fan box of claim 8, wherein each ofsaid side members includes a surface extending perpendicularly to saidlower surface, said side surfaces and said lower surface defining saidrecess, said side surfaces having at least one elongated outwardlyextending ribs thereon for providing frictional engagement with saidstructural member.
 10. A ceiling fan box of claim 9, wherein each ofsaid side surfaces includes a planar extension member having a surfacecoplanar with said side surfaces, and a hole therethrough for receivinga fastener therein for further securement of said box to said structuralmember.
 11. A ceiling fan box of claim 10, wherein said side memberseach have at least one wire entry apertures therethrough.
 12. A ceilingfan box of claim 11, wherein each of said side walls has a mount openingtherethrough for receiving a fastener to secure said box to a side ofsaid structural member.
 13. A ceiling fan box of claim 12, wherein eachsaid mount opening has a 45 degree angle from said surface of saidsidewall therethrough.
 14. A ceiling fan box for mounting on astructural member comprising: a body having a lower surface and a pairof spaced apart opposed side members defining a recess therebetween forreceiving said structural member therein, said body including a flangeextending outwardly from and fully circumferentially around a peripheryof said body, and spaced downwardly from an upper surface of said body;an aperture formed through said lower surface for receiving a fastenertherein for securement to said structural member for supporting saidbody thereon; and a pair of openings formed through said lower surfacefor receiving a respective pair of fan supporting fasteners therethroughfor directly securing a fan to said structural member.
 15. A ceiling fanbox of claim 14, wherein said aperture has a flattened surface forfurther securement of a fastener.
 16. A ceiling fan box of claim 15,wherein said side members each have at least one wire entry aperturestherethrough.
 17. A ceiling fan box of claim 16, wherein said flange hasa top surface including an insulating material for sealing said box witha ceiling wallboard.
 18. A ceiling fan box of claim 17, wherein saidlower surface has a pair of flexible members formed thereon forremovably securing fasteners until detached by a user.